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Heat Recovery Technologies for Combined Heat and Power in Oil Field

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Presentation on theme: "Heat Recovery Technologies for Combined Heat and Power in Oil Field"— Presentation transcript:

1 Heat Recovery Technologies for Combined Heat and Power in Oil Field
Fanxu Meng, PhD, PE - Research Associate DOE Upper-West CHP TAP Houston Advanced Research Center (HARC) Denver, CO October 31th, 2018

2 In Today’s Presentation:
DOE CHP Technical Assistance Partnerships (TAP) Overview of Combined Heat & Power (CHP) Heat Recovery Technologies in Oil Field Working with US DOE CHP TAPs

3 CHP Technical Assistance Partnerships (CHP TAPs)
End User Engagement Partner with strategic End Users to advance technical solutions using CHP as a cost effective and resilient way to ensure American competitiveness, utilize local fuels and enhance energy security. CHP TAPs offer fact-based, non-biased engineering support to manufacturing, commercial, institutional and federal facilities and campuses. Stakeholder Engagement Engage with strategic Stakeholders, including regulators, utilities, and policy makers, to identify and reduce the barriers to using CHP to advance regional efficiency, promote energy independence and enhance the nation’s resilient grid. CHP TAPs provide fact-based, non-biased education to advance sound CHP programs and policies. Technical Services As leading experts in CHP (as well as microgrids, heat to power, and district energy) the CHP TAPs work with sites to screen for CHP opportunities as well as provide advanced services to maximize the economic impact and reduce the risk of CHP from initial CHP screening to installation.

4 DOE CHP Deployment Program Contacts www.energy.gov/CHPTAP
Tarla T. Toomer, Ph.D. CHP Deployment Manager Office of Energy Efficiency and Renewable Energy U.S. Department of Energy Patti Garland DOE CHP TAP Coordinator [contractor] Ted Bronson

5 CHP Overview

6 CHP: A Key Part of Our Energy Future
Form of Distributed Generation (DG) An integrated system Located at or near a building / facility Provides at least a portion of the electrical load and Uses thermal energy for: Space Heating / Cooling Process Heating / Cooling Dehumidification Single, double and triple effect Mcogen and Tecogen CHP provides efficient, clean, reliable, affordable energy – today and for the future. Source:

7 CHP Recaptures Heat of Generation, Increasing Energy Efficiency, and Reducing GHGs
Fuel 100 units CHP 75% efficiency Total Efficiency ~ 75% 30 units Power Plant 32% efficiency (Including T&D) Onsite Boiler 80% efficiency 45 units Electricity Heat ~ 50% 94 units 56 units

8 What Are the Benefits of CHP?
CHP is more efficient than separate generation of electricity and heat Higher efficiency translates to lower operating cost, (but requires capital investment) Higher efficiency reduces emissions of pollutants CHP can also increase energy reliability and enhance power quality On-site electric generation reduces grid congestion and avoids distribution costs

9 Attractive CHP Markets
Industrial Chemicals Refining Food processing Petrochemicals Natural gas pipelines Pharmaceuticals Rubber and plastics Pulp and paper Commercial Data centers Hotels and casinos Multi-family housing Laundries Apartments Office buildings Refrigerated warehouses Restaurants Supermarkets Green buildings Institutional Hospitals Schools (K–12) Universities & colleges Wastewater treatment Correctional Facilities Agricultural Dairies Wood waste (biomass) Concentrated animal feeding operations

10 CHP Today in the United States
Existing CHP Capacity 81.3 GW of installed CHP at more than 4,400 industrial and commercial facilities 8% of U.S. Electric Generating Capacity; 14% of Manufacturing Avoids more than 1.8 quadrillion Btus of fuel consumption annually Avoids 241 million metric tons of CO2 compared to separate production

11 CHP in the U.S. by Technology
By Site – 4,434 Sites By Capacity – 81.3 GW

12 CHP in the U.S. by Fuel Type
By Site – 4,434 Sites By Capacity – 81.3 GW

13 CHP in the U.S. by State Source: DOE CHP Installation Database (U.S. installations as of December 31, 2017)

14 Finding the Best Candidates: Some or All of These Characteristics
High and constant thermal load Favorable spark spread Need for high reliability Concern over future electricity prices Interest in reducing environmental impact Planned facility expansion or new construction; or equipment replacement within the next 3-5 years

15 CHP Heat Recovery Technologies

16 Reciprocating Engines
CHP System Schematic Electricity On-Site Consumption Sold to Utility Prime Mover Reciprocating Engines Combustion Turbines Microturbines Steam Turbines Fuel Cells Fuel Natural Gas Propane Biogas Landfill Gas Coal Steam Waste Products Others Generator Thermal Steam Hot Water Space Heating Process Heating Space Cooling Process Cooling Refrigeration Dehumidification Heat Exchanger

17 CHP Top Cycle

18 Temperature Classification
High, > 1,200 °F (650 °C) Advantages: High-quality energy, diverse range of end-uses High-efficiency power generation High heat transfer rate per unit area Barriers: Thermal stresses on heat exchange materials Typical Recovery Methods: Preheat, steam generation Transfer to med-low temperature processes DOE, Waste Heat Recovery: Technology and Opportunities in U.S. Industry (2008)

19 Temperature Classification
Medium, ,200 °F ( °C) Advantages: More compatible with heat exchanger materials Practical for power generation Typical Recovery Methods: Preheat, steam generation Organic Rankine cycle for power generation Transfer to low temperature processes DOE, Waste Heat Recovery: Technology and Opportunities in U.S. Industry (2008)

20 Temperature Classification
Low, < 450 °F (< 230 °C) Advantages: Large quantities in numerous product streams Barriers Few end uses, low efficiency power generation Acidic and exchanger corrosion with low-temperature combustion exhausts Typical Recovery Methods: Space heating, domestic water heating Organic Rankine cycle Adsorption chiller DOE, Waste Heat Recovery: Technology and Opportunities in U.S. Industry (2008)

21 Rankine Cycle Heat Engine
Steam Rankine Cycle SRC is a proven-technology 50 kW – 100 MW ICF, Waste Heat to Power Market Assessment, (2015)

22 Organic Rankine Cycle ORC operates with low temperature heat sources, as low as 200 °F or below ORC has higher installed capital cost and O&M cost ICF, Waste Heat to Power Market Assessment, (2015)

23 Upstream Project Snapshot
Flare Gas to Electricity, Bakken, ND ElectraTherm partnered with Hess Corporation Application/Industry: Oil and Gas Upstream Capacity (MW): 65 kW Equipment: Organic Rankine Cycle Power +, hot water boiler Fuel Type: Flare Gas Recoverable heat temperature: °F Thermal Use: Electricity generation Installation Year: 2015 Environmental Benefits: CO, NOx and VOC reduction Upstream Project Snapshot ElectraTherm’s Waste Heat to Power Technology Reduces Flaring at Hess Oil Well

24 Mid-Stream Project Snapshot
Power from Compressor Station Waste Heat Northern Border Pipeline St. Anthony, ND Application/Industry: Natural Gas Pipeline Capacity: 5.5 MW Prime Mover: Gas turbine Fuel Type: Recovered waste heat Thermal Use: Unknown Installation Year: 2006 Energy Savings: $600,000/yr Highlights: In 2006, the Northern Border Pipeline (NBP) installed a waste heat to power (WHP) CHP system at their compressor station in St. Anthony, ND. The 5.5 megawatt system converts waste heat from the compressor into electricity using an Organic Rankine Cycle based power plant. ORMAT Technologies, Inc. owns and operates the plant, purchasing the waste heat from NBP and selling the electricity to nearby electric cooperatives. Following the success of the WHP system, NBP has worked with ORMAT to adopt similar WHP systems for other compressors along its pipeline, with systems now at 10 of the 16 compressor stations. Source:

25 Adsorption Chiller Typically operates with hot water ( °F) or low pressure steam (15 psig) DOE, Combined Heat and Power Technology Fact Sheet Series:

26 Desiccant Dehumidifier
Uses a special humidity-absorbing material called a desiccant “Recharged" to drive off the humidity, typically by heating it Suitable for high humidity levels at low temperatures Widely utilized in such as supermarket sector

27 Increasing Opportunities in Oil and Gas
Need for reliability Legislations and Regulations on GHG emissions and flaring Increasing energy intensity Growing power demand for expansions Social Responsibility

28 More Insights “Determining Opportunities for Combined Heat and Power (CHP) in the Oil Field” Andra Wilcox, Research Scientist at HARC Session “Clean Power in the Oilfield” 11:15 am, Oct 31st

29 Summary CHP is a proven technology in industrial facilities
It provides energy savings, reduced emissions, and opportunities for resiliency Proven technologies are commercially available and cover a full range of sizes and applications

30 Thank You! Questions? Fanxu Meng, PhD Gavin Dillingham, PhD
Research Associate Houston Adv. Research Center 8801 Gosling Rd The Woodlands TX 77381 Gavin Dillingham, PhD Program Director Houston Adv. Research Center 8801 Gosling Rd The Woodlands TX 77381

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